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INDUCTION TRAINING PROGRAM

(Green Valliey Industries Limited)
Village :Nongsning , East Jaintiya Hills
Meghalaya , 793200

Date of reporting : 08.04.2019

Date of submission : 22.04..2019

Submitted by: Virendra Kumar Singh

Designation: Asst. Engineer (Mech)
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CONTENTS
Sl. No Department Page No.
1 Human Resources 3
2 Process Department 3-13
3 Electrical and Instrumentation 13-15
4 Mechanical Department 15-16
5 Quality Control 16-18
6 Packing Plant, Logistic and Dispatch 18-19
7 Stores 20
8 Accounts & Commercial 21
9 Conclusion 22
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Day 1: Human Resources. (08/04/2019)

Responsibility: Shri. Vikash Mishra.
The induction program started from the Human Resources Department, where introduction to the company was made
by Mr. ChandanPadhy.
GNG Group was founded by Late MR. G. N. Agarwal and presently taken care of by Praveen Agarwal. Max Cement is
the brand of Green Valliey Industries Limited under GNG. The Plant and the registered Office is situated at Nongsning Village,
Meghalaya, with its Sales and Marketing Office at Guwahati, Assam and the Corporate office at Kolkata, West Bengal. The head
of the plant is Mr. V V Vyas.
The Human resource department is where computer and document related works are being done to compile
information about employees and recruitments and also to take care and calculate the wages of each employee. The department
is also responsible for recruitment and enhancing skills to the employees. Overall, for the social well-being of the employees and
a good working environment.

Day 2& 3: Process Department. (09 & 10/04/2019)

Responsible: Shri. P.J Rao
Process Department:They are responsible for maintaining the plant's process parameters (heat flow, mass flow, air flow and other
utilities) and suggest changes to accommodate some failures/breakages during plant operation, while minimizing cost.The process
department is responsible for the smooth functioning of the Plant, to produce the best cement. and operate all the function and
control the plant. And plant control by the CCR department (Central Control Room)
Such as : Feeding the raw material , Crusher operating , Raw mill operating , Kiln Operating , Coal Operating and cement mill
operating .
The Operators and attenders are present at the Plant to check and look for the proper functioning of the machines. Any
unusual sound or behavior observed by them is brought to notice to the CCR who commends on steps to be taken.
CCR Operation : The CCR Operator is responsible for the operation of different plant sections from the central control
room.

• Plant operation and optimizing the process parameters

• Co ordination with field people from CCR for smooth operation of the plant.
• Measurement of various process parameters along with Shift In-charge
• Recording of process parameters and plant log for the respective section

Cement Production Procedure:

The raw materials used for clinker production are Limestone (source of lime or Calcium), Black Shale (source of
alumina), Red Clay (source of silica) and Laterite (source of iron ore). The process of cement manufacturing begins from the
mining site or where the raw material is brought and stored.

1. The raw material used for making clinker are Lime stone, Red Clay-1(Iron), Clay-2(&laterite(Iron).
The first step in the manufacture of portland cement is to combine a variety of raw ingredients so that the resulting cement will
have the desired chemical composition. These ingredients are ground into small particles to make them more reactive, blended
together, and then the resulting raw mix is fed into a cement kiln which heats them to extremely high temperatures.
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Composition of Mixing raw mixing percentage.

1. Limestone – 82 – 84.50 %
2. Red Clay – 6.5 – 7.5 %
3. Sand – 5.25 – 6.76%
4. Laterite -0.68 - 1 % (If Needed)
The additives used for making cement are Gypsum,Red Soil(Flyash) etc.
Composition of Mixing Additives with clinker percentage.
1. Clinker – 76 %
2. Gypsum – 3 %
3. Flysash – 21 %
There are many types of Contents
1. Feeding & Crushing the Raw Material:The raw material is feeded into the crusher which reduces the size of the material
as required.
Double Rotor typeImpact Crusher (L&S)
a. Primary crusher
b. Secondary crusher
.
The raw material of limestone is dumped into the hopper and the Appron feeder is used to brings the material to the
feeder into the Compound crusher (230 TPH, actual capacity- 350), which has a Primary crusher and a Secondary crusher to
grind to a desirable size of up to 15-25mm. A Bag filter is attached to the crusher to reduce the dust emission.
Stacker stacks the material after crushing and goes to the Reclaimer section for pre-homogenization , i.e., maintaining a uniform
size collection for homogeneous feeding of limestone with the help of Harrows, which is a triangular shaped and a horizontally
movable machine with spikes at the end to cut into the piles. The uniform pile gets collected at the bottom, due to the movement
and the action of gravity, by buckets which is piled into the conveyor belt to the Raw mill section 1
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L/S CRUSHER (SECTION-A)

D G

A. HYWA
B. Dumping Hopper
C. Apron Feeder
D. Double Rotor Impact Crusher (L & S Crusher )
E. Transfer Chute
F. Troughed Conveyor (Convey No – 1021)
G. Suction Bag Filter
HYWA

1. A vehicle used for dumping Limestone and Lateriate from stockyard and mines to the Dumping Hopper
2. Capacity – 16 - 17 MT

DUMPING HOPPER
1. Dumping hopper collects limestone at a size of 1000 mm max. to deliver to Apron Feeder.
2. Capacity - 100 MT
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APRON FEEDER

1. Limestone from dumping hopper feed into Apron feeder to Impact Crusher.
2. Capacity – 350 TPH
3. Drive system through motor Gearbox Pair System
4. Motor Spec. 30 KW, 1000 RPM.
5. Bearing Type – Spherical Roller.
6. Spillage Conveyor is given below through pan of apron Feeder , when the limestone of small sizes are spilled through Pan of
apron feeder that collected and feed to the Crusher.
7. Drive system of spillage conveyor through motor gearbox pair system.

DOUBLE ROTOR IMPACT CRUSHER

1. The Crusher contains both primary and secondary rotor.

2. Max product size passing is 25 – 35 mm, for sizes differential there is a grinding path that we have to set manually.
3. The Hood mother plate are lined with High chrome Liner Plate for protection wear abrasion of mother plate.
4. Crusher contains Breaker Plates (Arm) and Blow bars (Rotor)
5. Rotor Dia – 1600mm Width 1500mm.
6. Capacity – 350 TPH (Achieved – 330TPH)
7. No of Blow bars – 06 Nos (Primary) 12 Nos (Secondary)
8. Nos of Breaker Arm – 02 Nos
9. Drive System through Motor , Drive transmission through V Belt.
10. V belt –for Primary Rotor – SPC-10600
for Secondery Rotor – SPC-8500
11. Motor for Primary Rotor – 350 KW
for Secondary Rotor – 420 KW
12. Bearing are Sperical. (Primary & Secondary- 22248 BKMBC3)
13. For Maintanance of the crusher there is hydraulic jack for opening frame of the crusher for removing jammed material and
check liner damage.

TRANSFER CHUTE

1. This chute is below the crusher outlet to transfer the crushed limestone to Troughed Conveyor(1021).
2. The chute is also lined with high chromium Liner for Wear protection of mother plate.
3. There is a inspection door available for maintenance of liner damages.
4. Chute outlet covered with skirtboard for prevention of spillage.

TROUGHED BELT CONVEYOR (1021)

1. Crushed Limestone got transfer from crusher through transfer chute into this belt conveyor for Stacker and Reclaimer
Section
2. Belt Material Grade – M24 Nylon
3. Width of the Belt- 800 mm
4. Capacity – 350 TPH
5. Speed – 1.5 m/s
6. Troughing Angle – 30 Degree
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STACKER AND RECLAIMER (SECTION – B)

CIRCUIT DIAGRAM G

Stockpile for Limestone

A B

Stockyard for Sandstone Stockyard for Clay Stockyard for Ironore

H I J J

K L

N O P Raw mill
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A – THROUGED CONVEYOR (1021)

B- STACKER CONVEYOR

C – STACKER

D – BRIDGE TYPE RECLAIMER

F - RECLAIMER TROUGHED CONVEYOR (1038)

G – LIMESTONE STOCK PILE

H – STOCKYARD FOR SANDSTONE

I – STOCKYARD FOR CLAY

J – STOCKYARD FOR IRON ORE

K – DUMP HOPPER (SAND STONE)

L – DUMP HOPPER (SAND STONE AND CLAY)

M – RECIPROCATING FEEDER

N – TROUGHED BELT CONVEYOR (SANDSTONE,CLAY & IRONORE)(1060)

O – TROUGHED BELT CONVEYOR(RAWMILL)(1038)

STACKER CONVEYOR

1. This Conveyor for stacking crushed limestone in Limestone Pile.

2. Capacity – 350 TPH
3. Belt Width – 800 mm
4. Drive Arrangement – Gearbox Coupled
5. Belt Grade M24 Nylon Stripped.

STACKER
1. It’s a Luffing type Stacker .
2. Capacity – 350 TPH
3. Belt Width – 800 mm
4. Material Stack Capacity – 6000 x 2
5. Total Travel Length – 90 m
6. Travel Speed – 30 m/min
7. Rail track span – 5 m
8. Total 8 wheel, 4 nos runner wheel and 4 nos drive wheel.

RECLAIMER
1. It’s a Bridge type Scrapper Reclaimer.
2. Capacity 250 TPH
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3. Scapper chain is of roller type.

4. Chain Speed – 0.61 m/s
5. Chain pitch – 315 mm
6. Drive System of the scrapper Chain.

LIMESTONE STOCK PILE

1. Crushed limestone are stocked in this pile.

2. Capacity – 6000 MT
3. Total Length – 41m
4. Total Height – 10 m
5. Total Base Width – 28 m

STOCKYARD FOR SANDSTONE

1. Sandstone are stocked in this yard

2. Capacity – 2000 T
3. Total Length – 15m
4. Total Height – 10 m
5. Total Base Width – 30 m

STOCKYARD FOR IRONORE

1. Ironore are stocked in this yard
2. Capacity – 2000 T
3. Total Length – 15m
4. Total Height – 10 m
5. Total Base Width – 30 m

STOCKYARD FOR CLAY

1. Clay are stocked in this yard
2. Capacity – 4000 T
3. Total Length – 30m
4. Total Height – 10 m
5. Total Base Width – 30m

DUMP HOPPER (SAND STONE & CLAY)

1. Raw material like sandstone and clay are dumped into this hopper for Raw mill
2. Capacity – 50 MT
3. Rod gate is given below it of dimension 800x1000(mm).

RECIPROCATING FEEDER

1. Feeder works on recipracting vibration for evenly and continuously transporting of material from hopper to conveyor.
2. For drive consist of motor tyred coupled to worm reducer .
3. Capacity 5 TPH

TROUGHED BELT CONVEYOR ( Sandstone, Clay & Ironore)(1060)

1. Material handled are sandstone, Clay, Ironore

2. Capacity – 75 TPH
3. Width of belt – 650 mm
4. Troughing Angle -30 degree
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5. Drive coupled through gear box

RECLAIMER BELT CONVEYOR (L&S)(1038)

1. Material handled are L&S ,

2. Capacity – 75 TPH
3. Width of belt – 650 mm
4. Total Length -80 m
5. Troughing Angle – 30 degree
6. Drive coupled through gear box

TROUGHED BELT CONVEYOR (L&S, Sandstone, Clay & Ironore)(1065)

1. Material handled are L&S,Sandstone, Clay& Ironore)

2. Capacity – 75 TPH
3. Width of belt – 650 mm
4. Total Length -80 m
5. Troughing Angle – 30 degree
6. Drive coupled through gear box

2. Raw Mill Section(Ball Mill Type) : There are four hoppers (250 MT, 150 MT, 100 MT, 120 MT) for the collection of
raw materials i.e., limestone, red clay, black shale, and laterite which is fed into the Weight Feeder and goes into the Grinding
mill, known as the Ball mill which uses a number of balls (Chromium), known as media, to crush and grind the material as they
rub against one another. The percentage of feeding is usually in the order of 80% for limestone, 7% for red clay, 6% for black
shale and 2% for laterite. The mill (100 TPH, actual capacity- 80 TPH) is of approximately 11 meters long and a diameter of 4.2
meters, it consists of two chambers, first, the drying chamber and later, the grinding chamber. The rotation of the mill is up to 20
RPM. The material then goes to the Separator, then to the cyclone where the coarse materials are sent back into the mill for
crushing again and the fine particles are sent to the Blending Silo with the help of Air slide through Bucket elevators. Dust
Handling system known as Reverse Air Bag House (RABH) are used here. The Blending silo (5000 MT) stores the grounded
raw mix.
A B C D
L M N

E F G H J

I
K
A. Limestone Hopper
B. Clay Hopper
C. Black Clay Hopper
D. Latralite Hopper
E. Limestone Weigh Conveyor
F. Clay Weigh Conveyor
G. Black Clay Weigh Conveyor
H. Latralite Weigh Conveyor
I. Raw Mill
J. Seperator
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K. Seperator CF Fan
L. Cyclones
M. Air Slides
N. Blending Silo

3. Coal Section (Ball Mill Type): The hopper (50 MT) stores the coal (25 mm) and from the weigh feeder goes to the Ball mill
inlet for grinding. The length of the mill (8 TPH) is approximately 6 meters long and 2.5 meters in diameter. The material then
goes to the Grit Separator, then the coarse materials are sent back into the mill for crushing again and the fine particles (90
microns) are sent to the two hoppers , one for kiln calcinations (firing) and the other for pre calcination (firing). A Bag filter is
used to reduce the dust emission. The coal section is an important part of cement plant. Which is used to burn of raw mix
material in kiln. Such as lime stone, red clay &laterite. Also moistures & fly ash is available in coal but there should be available
too much carbon percentage in coal. That coal is best.
The mill having two chamber i.e for drying and grinding ,here same for grinding media is used. Girth Gear is overlapped on the
mill having pinion gear coupled with 300 KW for main drive of pinion gear and for auxillary drive 11 KW motor is used
Contionious Lubrication system is implemented for girth gear and White metal bearing

Process of Coal Burning:

Coal is used as an energy source in cement production. Large amounts of energy are required to produce cement.

A
C E F
G
B
H
D

A. Coal Receiving Hopper

B. Coal Mill
C. Seperator
D. C F Fan
E. Pre-Calciner Hopper
F. Kiln Calciner Hopper

4. Kiln Process : A typical process of manufacture consists of three stages: grinding a mixture of limestone and clay or shale to
make a fine "rawmix" , heating the rawmix to sintering temperature (up to 1450 °C) in a cement kiln; grinding the resulting clinker
to make cement. Bucket elevator takes the raw materials from the Blending Silo to the Preheater for heating, where 60% of the
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firing is already done. The pre heated material goes into the kiln (1300 TPH, actual capacity 1000 TPH), which is 40 meters long
and 3.2 meters in diameter and a tilt of 3o, to be heated up to 1400oC which melts the raw mix and the final product at the outlet
of the kiln is known as clinker. Cooling section, where the hot clinker is cooled with the help of seven cooling fans (Great cooler).
The hot air is reused and is sent to the preheating section and also to the RABH. The deep Bucket (or Van) conveyors carry the
cooled clinker to be sent and stored at the Clinker Stock Pile (CSP). Electrostatic Precipitators (ESP), consisting of ten chambers,
which has an efficiency of 90% is attached here to reduce the dust emission.

Dry Kiln with multistage Pre-heaters and Precalcination Schematic

Preheater Tower( 5 Stage Cyclones)

Rotary KILN

Great Cooler Chamber

6. Cement Mill : A cement mill is the equipment used to grind the hard, nodular clinker from the cement kiln into the
fine grey powder that is cement. Most cement is currently ground in ball mills and also vertical roller mills. Cement is typically
made from limestone and clay or shale.the cement mill is also most useful for making the best quality cement. And the use of
cement mill grinding of clinker.
The cement mill (70 TPH) which is of length 13.6 meters and diameter 3.6 meters. Four cyclones are attached with two main bag
filters to reduce the dust. There are two air slides and two silos for PPC and OPC. The types of cement produced are as below:

 PPC (Portland Pozzolona Cement): Mixture of Clinker, Gypsum (Limestone) and fly ash (calcined clay) in the
proportion of 78%, 2% and 20% respectively.
 OPC (Ordinary Portland Cement) 43 Grade and 53 Grade: Mixture of Clinker and Gypsum (Limestone) in the
proportion of 95% and 5%. The difference in the two grades is that, after 28 days of making a plaster, the compressive
strength of OPC 43 is 43 MPa and that of OPC 53 is 53 MPa. The setting time is more in OPC 43 than OPC 53.

Stock capacity of
raw & finished
material

CSP OPC Silo PPCSilo Stacker Pile Stacker Blending Silo

Capacity capacity
18000 5000 5000 Tonne 4500 350 5000 Tonne
Tonne
Tonne Tonne Tonne
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There are two types of cement:

1. OPC : Ordinary Portland cement
There are two Grades of OPC:
a. Cement 43
b. Cement 53
2. PPC : Portland pozolana cement
a. Bag color of White
b. Bag color of White Green

☞ Day 4 & 5: Electrical and Instrumentation. (11/04/2019 & 12/04/2019)

Responsible: ( Mr. Pankaj Jha & Mr. Abdul Karim)

Electrical Department : The discipline of Electrical and Instrumentation Engineering deals with the design of devices to measure
physical quantities such as pressure, flow and temperature. It basically focuses on the study and application of electricity,
electronics, and electromagnetism. And we purchase the electricity by the government for use the manufacturing unit as per
required.

There are many contents below:

1. Power Distribution Systems : Electric power distribution is the final stage in the delivery of electric power.We supply
the power to all over plant in different place as per required.
Power distribution system diagrammention below:

Power Distribution system

Station
↓
LC - 2 (Power supply only in Raw mill, coalmill, Kiln, Preheater, Silo & CCR Office)
↓

LC - 1 LC - 3
(Power supply only in crusher & (Power supply only in cement mill &pcking plant)
Reclaimer)

2. Power Purchase Indent : We purchase the power by the government as per production and company budget on
daily base MHW. There are two system of power purchase.
a. Open access : In the open access we purchase the power on daily base. In that condition power purchase price
sometimes increase and decrease. And always we purchase the power from third party.
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b. Close access : In the close access we purchase the power by the government as per monthly base. In that condition
always price and quantity is fixed.

3. Complaint Work Flow : Complaint work flow is mention below with diagram.

Complain CCR Operation

Mechanical or other
Close the complain Complaint receive by the shift department
EDI

Solve the problem

Inform to CCR

Problem solved
YES

NO HOD Comercial

4. Energy Management System : An energy management system (EMS) is a system of computer-aided tools used by
operators of electric utility grids to monitor, control, and optimize the performance of the generation and/or
transmission system.

a. Electric consume for crusher - 250 KW

b. Electric consume for Raw material handling (Reclaimer - 55 to 85 KW
c. Electric consume for Raw mill - 2200 to 2300 KW
d. Electric consume for Coal mill - 400 to 480 KW
e. Electric consume forCement mill - 2100 to 2200 KW
f. Electric consume forPacking plant - 100 to 110 KW
g. Electric consume for Kiln - 1500 to 1600 KW
h. Electric consume for Utility pump (Air and water supply - 5 to 10 KW
i. Electric consume for Plant & Lighting - 15 to 50 KW
j. Electric consume for Colony lighting - 150 to 250 KW
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5. Electrical Safety : Electrical Safety Related Work Practices. Safety related work practices are employed to
prevent electric shock or other injuries resulting from either direct or indirect electrical contact when work is performed
near or on equipment or circuits which are or may be energized
There are different types of electrical safety tools:
a. Safety Helmet
b. Safety shoes
c. Hand Glaps
d. LC work
e. Proper work of LC
f. Safety belt
c.

☞ Day 6 & 7: Mechanical Department. (13/04/2019 & 15/04/2019)

Responsible: (Shri. Arvind Jindal)

Mechanical Department: Mechanical are in operation, as maintenance, project, procurement, and based on seniority they have
higher responsibility and authority. Mechanical Department repair and maintenance of all manufacturing parts which continue
usable for manufacturing and replace the parts which damaged with the help of manpower and workshop. The main roll of
Mechanical department of any manufacturing unit. Without mechanical activities we can not do the good production. This is also
part of manufacturing unit.

1. Mechanical Workshop Operation : Machine play a very important role in a workshop where metal working or
woodworking tasks are performed. By installing these, various tasks like cutting, shaping, drilling etc. which are to be
carried out on harder wood and metal surfaces can be easily accomplished.
There are many different type of mechanical work shop machine

a. Lathe Machine : we can design, cutting and bore any types of parts with the help of lathe machine. Such as :
shaft, plate etc.
b. Drill Machine : we can drill of any machinery parts with the help of drill machine.

c. Hydraulic press : we use the hydraulic press in overall plant maintenance.

d. Shaping Machine: It is used for cutting curves, angles and various shapes from the work piece.

e. Measuring tools for workshop: we can measure any types of machine and parts. This is very important category.

f. Hammer and mallets for workshop : we use the hammer and mallets for any repair parts.

g. Milling Machine for Workshop :A milling machine is often misunderstood as a lathe work.

h. Grinding Machine:Tasks like roughing or finishing of surfaces, finishing internal cylinders or bores, sharpening the
cutting tools, removing rough projections from castings, cleaning, polishing, and buffing surfaces all are achieved
through grinding equipment’s.
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2. Functioning of various mechanical equipment : we use the bearing function to be reduce the equipment eviction and
smoothly running of equipment. And bearing set in housing. Sleeves work to lock the inner race dia. And plumber block
to the housing and bearing.

3. Type of Maintenance and their planning : there are two types of maintenance.

a. Preventive or schedule maintenance: Preventive and schedule maintenance where equipment or facilities are
inspected. Maintenance and protected before break down or other problem occur.
b. Corrective maintenance : Corrective maintenance where equipment is repaired and replaced after break down.
c. Daily equipment checking : we check all the parts of manufacturing unit in daily base.

4. On the Job Safety Practice : The safety is very important for Mechanical work in plant. Always should be done the
work with safety.

There are many different types of safety things

Such as – cotton cloth, helmet, safety shoes, hand gloves of leather, safety belt, welding nose mass and welding helmet.

☞ Day 8 : Quality Control. (16/04/2019)

Responsible: ( Shri Prashant kumar Panigrahi)

Quality Control Department:Quality control is an important aspect of cement production.Quality control of the slurry in
the cement industry is based on weight ratio control of raw materials. Raw materials composition is usually assumed.
such as : clinker testing , red clay testing, black clay testing, laterite testing,raw mix material testing, lime stone testing and coal
testing

1. Quality Checking parameters of raw material received :

2.
Raw Material Testing
Lime stone Red Clay Black Clay Laterite

Silica 5.25% Silica 70% Silica 55% Silica 35%

Alumina 1.10% Alumina 1.20% Alumina 15% Alumina 3.5%

Iron 1.35% Iron 0.40% Iron 8% Iron 35%

Calcium 49.75% Calcium 9.0% Calcium 2.00% Calcium

Oxide Oxide Oxide Oxide
 Page 17 of 22

Magnesium 0.95% Magnesium 0.2% Magnesium 0.52% Magnesium

Oxide Oxide Oxide Oxide

Clinker final testing Percentage for OPC & PPC

Silica Alumina iron Calcium Magnesium

12.40 % 2.80 % 2.60 % 43.80 % 1.30 %

OPC:Clinker (74%) + lime stone (2%) + fly ash (5%)

I.S.T of OPC - 125
F.S.T of OPC- 135
PPC : Clinker (80%) + lime stone (3%) + fly ash (23%)
I.S.T of PPC - 169
F.S.T of PPC- 210(74%) + lime stone (2%) + fly ash (5%)

Surface testing of OPC& PPC Cement:

OPC Surface: 320 meter per square

PPC Surface: 380 meter per square

Strength & setting of Cement

Types of cement
Setting Strength
OPC I.S.T- F.S.T- 3 days-27 7 days-37 mpa 28 days -53 mpa
125 135 Mpa
PPC I.S.T- F.S.T- 3 days-16 7 days-22 mpa 28 days -33 mpa
169 210 Mpa

Coal testing

Fly ash Carbon Moisture

 Page 18 of 22

20% 70% 10%

3. Material stock management: Stock management is the practice of ordering, storing, tracking, and
controlling inventory. Stock management applies to every product a business uses to produce its products or services –
from raw materials to finished goods. In other words, stock management covers every aspect of a business's inventory.
That’s why we keep the advance stock of such a material – lime stone pile stock, coal stock, raw mix stock, clinker stock,
clay stock, laterite stock etc.

4. Pile making in Lime Stone :The raw material is feeded into the crusher which reduces the size of the material as
required.And after crushed the lime stone keep in the pile store with the help of stacker.

5. Supply of Quality coal to coal mill: First of all testing and quality checking of coal and crushed. Again transferred to
coal mill to burn of raw mix material.

6. Raw mix design parameters :

7.
Raw Mix Design Parameters

Silica Alumina iron Calcium Magnesium

12.40 % 2.80 % 2.60 % 43.80 % 1.30 %

8. DPR Generation : DPR (Daily Production Report) purpose to submit the daily base production report of raw
material stock, lime stone stock, coal stock, clinker stock, raw mill stock.

☞ Day 9 & 10: Packing Plant ,L&D. (17/04/2019 – 18/04/2019)

Responsible: ( Shri. Sanjiv Rawalwasia)

 Packing Plant, L&D: A packing plant is a company that processes and packs cement, to be sold. Define
packaging material types it can be anything like boxes. Type, plant determination, packaging material category, generate
delivery. There should be Dispatch the material after good packing. Without packing the material can be damage. And
also can be loss to company. So that packing, L&D is also mail part of any company.

1. Transport System: A transport system is a means by which materials are moved ('transported') from an exchange surface
or exchange surfaces to cells* located throughout the organism.
a. Vehicle arrange
b. Transport cost
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c. Loading Process
d. Documentation
e. Weight to vehicle
f. Material dispatched with safety
g. Time to time dispatch

2. Documentation & Invoice checking against packing:An invoice, bill or tab is a commercial document issued by a seller to
a buyer, relating to a sale transaction and indicating the products, quantities, and agreed prices for products or services
the seller had provided the buyer.
Contain are mention below:

a. Invoice checking
b. Invoice quantity
c. Invoice basic value
d. Product weight
e. Invoice number
f. Tax with total value
g. Party name
h. Party G.S.T number
i. Material type
j. E way bill

3. Stock analysis as per demand generated by the marketing team: The stock analysis depend on the order of marketing
team.Stock analysis is the evaluation of a particular trading instrument, an investment sector, or the market as a
whole. Stock analysts attempt to determine the future activity of an instrument, sector, or market.

4. Bag Management (HDPE-stock checking): (High Density polymer ethylene plastic bag) generally, cement bags
are stored on site temporarily during construction of a building. To avoid poor quality of construction; careful
transportation and handling of all the building materials is essential. By following proper precautions for
cement bag handling, breakages and losses can be reduced to a minimum, resulting in saving of time and
money. Here we have information on cement bag handling at the site to avoid wastage. And HDPE (High
Density polymer ethylene plastic bag) is best quality. HDPE is a thermoplastic polymer produced from the
monomer ethylene with a high strength density ratio.

5. Weigh Bridge Management: The machine for weighing vehicle and their load. A weighbridge accuracy weighing
balance to the truck load scale. First vacant vehicle and second loaded vehicle weighbridge.Weighing bridges used for
multiple purpose such as determining bulk quantities.

6. Packing Plant Processing: After grinding the cement to the required fines, it will be stored in the packing house silo.
And when the Lorries are placed for loading. The cement from the silo will be withdraw to the electronic rotary packer
where in there will be nozzles to insert the spout of the HDPE bag, and the cement will be filled as soon as the weight
become 50 kg. The bags will be closed and the packed cement bag will be dropped in belt conveyor which will be going
up to the loading point of the lorry and load men will be pulling the bag and put in the lorry in a stacking manner in such
a way they can count.

☞ Day 12 : Stores Department. (19/04/2019)

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Responsible: ( Shri . Anand Sharma)

Store Department:A retail manager (or store manager) is the person ultimately responsible for the day-to-day operations
(or management) of a retail store. All employees working in the store report to the retail/store manager. Stores management is
part of the overall function of materials management. And highest amount of cost reduction can be done in this area only. Hence
stores play a major role as far a company is concerned. And if this raw material are not stored efficiently they will get deteriorate
and thereby causing big loss to the company.

There are various section such as:

Receiving section
Tool store
Raw material store
Mechanical store
Electrical store
General store
1. Material Classification: Good store-keeping requires proper classification and codification of various items of stores on
stock. Stores are generally classified either by their nature or by their usage. The former method of classification or
classification by the nature of materials is most commonly used.

To raise separate purchase requisition for different types of materials.

To group together stock control cards for materials of identical nature, e.g., all electrical items together, all oils together,
To send out separate enquiries for different types of materials such as steel, electrical items, hard ware etc.
To keep different types of goods separately as there are separate classes for different types of goods.

2. Cost Analysis: Cost analysis is the process of analysis business decisions. Cost analysis is the process of modeling costs
to support strategic planning, decision making ad cost reduction. The store manager inform to management about expense
cost and purchase cost.

3. Storage Type Analysis: Storage Analysis is the process of all material collect and kept in the store house with different item
wise.

a. Electrical parts
b. Mechanical parts
c. General product

4. Waste Analysis:Waste Analysis involves identifying, quantifying, eliminating and preventing waste in manufacturing, service
and office environments.

☞ Day 13: Accounts & Commercial Department. (20/04/2019)

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Responsible: ( Shri. Tarun Debnath & Shri . Rupesh Misra)

 Commercial : Commercial management is "the identification and development of business opportunities and the
profitable management of projects and contracts, from inception to completion." Commercial management within an
organization is applied only at policy levels.
 Accounts : Financial records of an organization that register all financial transactions, and must be kept at its principal
office or place of business.
The Account section is responsible for money handling, the expenditure, budget for management and keeping the
records of billing. It offers support to all the other departments in the background financially. The income of the
employees is generated by this department as per the details from the Human Resource Department and is sent to the
individual accounts.
The GST (Goods and Service Tax) plays an important role as it has become mandatory in the field of business.
The contract or business is initiated with the inspection of GST and the checking of other relevant documents. With the
introduction of GST, the number of taxes levied on goods is combined and reduced, doing away with separate taxes such
as Sales tax, excise, VAT, etc. The Government office is located in Shillong with a sub office at DC office in Khliehriat.
The GST number of the Green Valliey Industries is 17ACCG900D1Z3. The GST rate charged on cement is 28%.

1. Plant MIS : MIS is management information system.The report is usually submitted by all departments to Manager
every month. Management information system is used for generating reports including inventory status reports, financial
statements, performance reports etc. MIS reports also support decision making and it helps to integrate the decision
maker and the quantitative model being used.MIS submitted in also quarterly and daily base performance.
6

2. Procurement Process: A Procurement Management Process, orProcurement Process, is a method by which items are
purchased from external suppliers. Theprocurement management process involves managing the ordering, receipt, review
and approval of items from suppliers.

3. Tax Liability Calculation :The liability is generally calculated by multiplying the taxable event by the tax rate. Tax
liabilities are current liabilities.We can calculate tax liability as a percentage of the total taxable event.
Different types of tax liability below
a. Income Tax Liability
b. Sale Tax Liability
c. Business Tax Liability
d. Purchase Tax Liability

Thank You………..
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CONCLUSION
The visit to the various departments and the plant has increased my insight on the industries and its functioning. The
different department acts like the vital human organs of the human body for the production of the best output and work hand in
hand. Constant check on the equipment and data are collected and on-site monitoring is done efficiently.
Safety priority is maintained at the plant with the employees being issued with safety helmets, masks and steel toed shoes.
The plant has Bag house filters at release points and at every dust emission prone areas. Reverse Bag House filters are
installed to control dust emission. ESP is also installed which is a highly efficient dust controlling device. The Reduce-Reuse-
Recycle mantra is practiced here such as in the cycle of hot gas produced from the Pyro section, i.e., Kiln section, in the cooling
of clinker, for pre heating of raw materials, drying of materials before grinding and functioning of ESP, and also the construction
of two STPs (Sewage Treatment Plants) to recycle the domestic waste water. The whole process in the plant takes place in a
closed system with the help of suction fans which sucks air from different points and the gas before releasing goes through all the
filters attached to emit treated and least polluted air.
The quality of the output of cement is kept at the highest just as the quantity is. Constant monitoring of the raw material
and the finished product as well as the packaging bags are done to satisfy the consumers. The dispatches of the finished products
are also done systematically so that it reaches every buyer on time.
The segregation of the time of work into four sections is very systematic for the continuous functioning of the industry:
Shift A : 6:00 am to 2:00 pm
Shift B : 2:00 pm to 10:00 pm
Shift C : 10:00 pm to 6:00 am
General Shift : 8:00 am to 5:30 pm

A friendly working environment is exhibited by all the employees enabling the steady functioning of every individual.
I would like to thank all the heads and manager of each and every department and all the employees who whole
heartedly shared their knowledge, ideas and views and also imbibed in me the power of unity, and sincerity, the true spirit of
GVIL. My sincere gratitude to Shri Chandan Padhy, who continually encouraged me and took me to all the concerned
departments for the successful completion of this program. I would also like to convey my gratitude to the heads of the GVIL for
giving me such an invaluable experience and exposure. I shall keep the teachings and lessons learnt from this program etched in
my memory. I am thrilled to serve the company to the best of my capabilities and always strive to keep learning.
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